Methods of manufacturing toothbrushes

Abstract

A method is provided for manufacturing a function element carrier with function elements, for example, individual tufts made up of bristles and/or massage elements, interproximal cleaning elements, or other elements designed to be fastened to a toothbrush and also perform special functions. The function elements are equipped at their ends intended for anchoring in a toothbrush with an anchor, retainer or axle element. The method includes: (a) inserting several function elements in corresponding recesses of an injection mold, said injection mold being connected via grid or bar shaped channels formed in a die to recesses in the areas of the anchoring ends of the function elements; (b) filling the grid or bar shaped channels with liquefied plastic material and injecting said material at the anchoring ends of the function elements or embedding them therein; and (c) allowing the plastic material to cool and removing a function element carrier made up of a grid or bar shaped plastic frame and the function elements. Function element carriers and toothbrushes are also provided.

1 . A method of manufacturing a function element carrier including function elements, said function elements being equipped at their ends intended for anchoring in a toothbrush with an anchor, retainer or axle element, said method comprising the following steps: 
 inserting several function elements in corresponding recesses of an injection mold, said injection mold being connected via grid or bar shaped channels formed in a die to recesses in the areas of the anchoring ends of the function elements;    filling the grid or bar shaped channels with liquefied plastic material and injecting said material at the anchoring ends of the function elements or embedding them therein; and    allowing the plastic material to cool and removing a function element carrier comprising a grid or bar shaped plastic frame and the function elements.    
   
   
       2 . The method according to  claim 1 , comprising, in a next step, transferring the function element carrier to a further processing station in which the function elements are severed from the plastic frame, and subsequently the anchoring ends of the function elements are secured in a brush holder.  
   
   
       3 . The method according to  claim 1  or  2 , wherein the grid or rod shaped plastic frame includes grid bars and grid points between which tapers are formed.  
   
   
       4 . The method according to  claim 1 , wherein additional assembly aids or function faces are injection molded on the function elements.  
   
   
       5 . The method according to  claim 4 , wherein said assembly aids or function faces are configured as anchors or motion axles.  
   
   
       6 . The method according to  claim 1 , wherein the function elements and the plastic frame are fabricated from dissimilar plastic materials.  
   
   
       7 . The method according to  claim 1 , wherein the function elements are equipped with undercuts for securing to the plastic frame.  
   
   
       8 . The method according to  claim 1 , comprising in a next step transferring the function element carrier to a further processing station in which said carrier is embedded in a brush holder by injection molding plastic material around the carrier, such that subsequently only the anchoring ends of the function elements are enclosed by the brush holder.  
   
   
       9 . The method according to  claim 8 , wherein the grid or rod shaped plastic frame is made up of grid bars forming grid points at the intersections, between which tapers are formed, and wherein the plastic frame is deformed before being embedded in the molding material of the bristle holder so that the function elements assume their desired position in the brush holder following embedding.  
   
   
       10 . The method according to  claim 1  or  8 , wherein various function elements of elastomer plastic are provided on the plastic frame.  
   
   
       11 . The method according to  claim 1  wherein the function elements include elements selected from the group consisting of tufts of bristles, massage elements, and interproximal elements.  
   
   
       12 - 21 . (canceled)